Weldable paint composition

ABSTRACT

A weldable paint composition comprising a film forming resin and containing a hard metal, such as, Fe, Ni, Co, Cr, Mn and their alloys in powder form and a soft metal, such as, Al, Zn, Pb, Cu, Cd, Mg, Ag, Sn and their alloys in powder form and/or a soft metal equivalent substance, such as, graphite.

[Jited Stats Matsuda et a1.

atent [1 1 Sept. 9, 1975 [54] WELDABLE PAINT COMPOSITION [73] Assignee: Nippon Steel Corporation, Tokyo,

Japan [22] Filed: Oct. 5, 1972 '[21] Appl. No.: 295,199

[52] U.S. Cl. 252/503; 117/226; 117/227; 117/232; 252/512; 252/513; 252/514 [51] Int. Cl. H0lb 1/00 [58] Field of Search 252/512, 513, 514, 503; 117/227, 226, 232; 106/290; 29/192 R [56] References Cited UNITED STATES PATENTS 2,280,135 4/1942 Ward 252/512 2,321,587 6/1943 Davie et al.... 252/512 X 3,099,578 7/1963 Hunter 252/503 X 3,117,883 l/1964 Gilchrist 106/290 X 3,173,885 3/1965 Short 117/227 X 3,332,860 7/1967 Diebold et a1. 117/227 3,410,722 ll/l968 Flanders et al. 252/512 X 3,484,284 12/1969 Dates et a1. 117/227 X 3,493,369 2/1970 Busch et a1. 252/512 X 3,503,882 3/1970 Fitch 106/290 X 3,717,509 2/1973 Palm et a1... 117/227 X 3,719,610 3/1973 Prentice 252/513 FOREIGN PATENTS OR APPLICATIONS 431,641 7/ 1935 United Kingdom Primary Examiner-Benjamin R. Padgett Assistant ExaminerR. E. Schafer Attorney, Agent, or FirmToren, McGeady and Stanger [5 7] ABSTRACT A weldable paint composition comprising a film forming resin and containing a hard metal, such as, Fe, Ni, Co, Cr, Mn and their alloys in powder form and a soft metal, such as, Al, Zn, Pb, Cu, Cd, Mg, Ag, Sn and their alloys in powder form and/or a soft metal equivalent substance, such as, graphite.

7 Claims, N0 Drawings WELDABLE PAINT COMPOSITION This invention relates to a weldable paint composition, and more particularly relates to a paint composia tion for coating to obtain a weldable paint coated steel surface for use in electrical-resistance welding processes.

In conventional press-forming and coating of a steel sheet, the following procedures are used:

1. press-forming coating joining (construction) or 2. press-forming joining (construction) coating.

In order to give complete air-tightness and excellent strength of the joints, an electrical-resistance welding process is usually used, but there are certain applications in which such a welding process is not suitable. For example, in the first process mentioned above, it is difficult to weld steel sheets coated with a paint which does not have sufficient conductivity. In the second process mentioned above, it is difficult to make a uniform coating on welded steel sheet products.

An object of the present invention is to provide a new weldable paint composition for coating steel sheets before the press-forming and welding steps.

A weldable paint containing conductive, substances (generally, they are metals, aluminium paste, zinc powder and so on) is conventionally known.

In case of the conventional weldable-paint, the most suitable welding conditions depend on the composition of paint (the volume ratio of resins and metal). A prior publication teaches that the use of a paint containing 40 volume parts or more of metal powder per 100 volume parts of resin is needed to obtain sufficient weldability for coating on steel sheets. However, this paint has a defect that it has poor paint adhesion after forming, particularly after press-forming.

Table I shows results of the conventional paint.

Table 1 Relation between surface appearance and Aluminium Content in the Aluminiumcontaining paint Al content* Appearance of the Paint Film Surface 62 fairly good 50 good 30 excellent *The values mean volume part of Aluminium per I volume parts of Resin As is clear from the above results, it is obvious that it is desirable to keep the content of the metal in the paint as low as possible.

The present invention provides a paint composition which gives weldability and good paint properties with the lowest possible content of metals.

The paint of this invention is composed of a resin for film forming and the following combinations of metals:

1. one or more metals in powder form, selected from the hard metal group consisting of Fe, Ni, Co, Cr,

Mn and their alloys, and

one or more metals in powder form selected from the electrically conductive soft metal group con sisting of Al, Zn, Pb, Cu, Cd, Mg, Ag, Sn and their alloys or 2. one or more metals in powder form selected from the hard metal group consisting of Fe, Ni, Co, Cr, Mn and their alloys and 1 soft-metal'equivalent substance such as graphite.

3. one or more metals in powder form selected from the hard metal group consisting of Fe, Ni, Co, Cr, Mn and their alloys, one or more metals in powder form selected from the electrically conductive soft metal group consisting of Al, Zn, Pb, Cu, Cd, Mg, Ag, Sn and their alloys and a soft-metal equivalent substance, such as, graphite.

The mixing ratio of the resin and the metal powders is as follows:

More than 8 volume parts of the metal powder per volume part of the resin. The soft metal and the soft-metal equivalent substance used in this invention means a conductive substance deformable plastically by the welding pressure (about 1,200 to 2,500 kglcm in resistant welding and the hard metals mean conductive substance which undergoes substantially no deformation plastically by the I welding pressure (about 1,200 to 2,500 kg/cm In the conventional weldable paint, only a soft metal powder, such as, aluminium paste and zinc powder is used as the conductive substance. In such a case it is impossible to avoid the presence of the resin between the soft metal powder which should be in surface to surface contact when subjected to plastic deformation unless the metal is added in such a high amount that the film properties deteriorate.

The feature of the present invention resides in the addition of hard metal powders along with the soft metal powders. When the soft and hard metal powders coexist in the paint, electric conductivity is assured by contact between the metal particles.

It appears that the reason for this is that when the sheet steel coated with the present paint is welded, even if the resin is present between the metal particles, the hard metal particles break through the resin when welding pressure is applied, so that many spot contacts between at least the hard metal particles and many surface contacts between the hard and the soft metal particles are assured.

Consequently, the present paint coating has excellent electro resistance weldability in spite of very low metal powder content as compared with the conventional paint.

Thepresent inventive paint will be compared with respect of spot weldability with a conventional weldable paint containing only aluminium paste.

Table 2 Metal Powder Content* lnventive** Conventional *Volume part per H10 volume parts of resin Mixed with Feowder and Al-paste l l) Remarks:@: excellent. 0: good, X: bad

substance is 1 4 to 4 l in view of weldability and film quality ld 300 k The size of the metal powders does not affect weldpmbur 7'5 jg ijsgt Spot ability, but is preferable that the grain size is finer than elding time: 10 cycle 200 mesh. I

The resin for the film formation may be selected oph results Showed p Weldmg was Satlsfactonly tionally in connection with the upper coat since the Obtamcdpresent paint coating is used as precoatmg according to EXAMPLE 3 (Spot welding) the procedure used.

In this invention, polyester, vinyl-acrylic, thermosetting acrylic resins, epoxy resin and so on may be used as the vehicle. These are mixed with the metal powders Paint coating of the following composition was applied to 0.8 mm thick cold steel sheet.

in any type of solvent paint, water soluble, or water dispersion paints. Plasticizers and/or organic pigments 5 Heat curable acrylic resin: 100 volume parts may be added to the paint composition in a suitable pmvde' 8 Metal powders range, and the paint coating may be effected by a roll- Fe powder 8 er-coater, spraying and brushing. Solvents and others 300 The range of coating thickness is preferably between 8 and the paint coating may be applied to steel sheets and strips and other plated or chemically treated metal sheets and strips.

The proportion of the metal powder to the resin may welding pressure: 300 kg/one s ot be changed depending on the metal sheet to be coated. time: z 'i iit Spot For example, in case of a zinc-plated steel sheet, the 5 content of the metal powder is more than volume The results Showed good Spot welding parts per hundred volume parts of the resin to improve the corrosion resistance. Further a protective pigment 20 Welding was done under the following conditions:

EXAMPLE 4 (seam welding) may be add d- The paint coating of Example 2 or 3 was applied to Examples of the present invention will be set forth 30 0.8 mm thick steel sheet and seam welding was effected here under. under the following conditions:

EXAMPLE 1 (spot welding) I I I r Welding pressure: 400 kg The pa nt coating having the following composition 3s current: 15 KA was applied to 0.8 mm thick cold steel sheet. On-off cycle 2 4 cycles The results showed good seam welding.

Polyester resin I00 volume parts EXAMPLE 5 Al powder 25 40 Metal po\vders( Paint coating of the following composition was ap- FC PUwdcr 35 plied to 0.8 mm thick cold steel sheet. Solvents and others 400 Welding was effected under the following conditions. Polyester resin: 100 volume parts Pb powder 6 Metal powders Fe powder 6 Solvents and others 400 spot welding pressure: 300 kg/one spot amount of current: 8.0 KA/one spot fldmg Cycle Welding was done under the following conditions:

The results showed a satisfactory welding was obtained. welding pressure: 300 kg/one spot current: 8 8.5 KA/one spot gs welding time: 10 cycle EXAMPLE 2 (spot welding) The results showed ood s ot weldin Paint coating of the following composition was apg p g plied to 0.8 mm thick cold steel sheet. EXAMPLE 6 Paint coating of the following composition was applied to 0.8 mm thick cold steel sheet.

Vinyl modified acryl resin IOU volume parts Zn powder l5 Metal powders Epoxy resin: 100 volume part Fe powder l5 Al powder 10 Solvents and others 350 Metal powders Fe powder 20 Corrosion-protective pigment (Zinc chromate) 4 And welding was done under the following conditions: s l d others 300 Welding was effected under the following conditions:

300 400 kg/one Spot 7 8.0 KA/one spot 5 l0 cycle welding pressure: current: welding time:

The result showed very good weldability.

EXAMPLE 7 Various metal sheets were coated with the weldable paint of Example 1 and welding was done under the following conditions:

300 400 kg/one spot 7 8.0 KA/one spot 10 cycle Welding pressure: Current: Welding time:

The metal sheets coated in this example included a slightly Zinc-plated steel sheet (0.5 3g/m plating) treated in organic chromate solution or inorganic chromate solution, electrically surface-treated steel sheets and phosphated Zinc-plated steel sheets.

The results were satisfactory.

EXAMPLE 8 An 0.65 mm thick Zinc-plated steel sheet (plating weight of 60 305 g/m was coated with a paint of the following composition:

The results were very satisfactory.

EXAMPLE 9 An 0.8 mm thick tin-plated steel sheet was coated (plating weight: 80 100g/m with the paint of Exam- 5O ple 8 and welding was effected under the welding conditions of Example 8.

The results were satisfactory.

EXAMPLE 10 An 0.8 mm thick aluminium-plated steel sheet (plating weight: g/m was coated with the paint of Example 8 and welding was done under the welding conditions of Example 8.

The results showed good weldability.

What is claimed is:

1. In a weldable paint composition comprising a film forming resin and a conductive metal, the improvement wherein the metal comprises a mixture of a soft metal selected from the group consisting of Al, Zn, Pb, Cu, Cd, Mg, Ag, Sn, and alloys of said soft metals with each other; and a hard metal selected from the group consisting of Fe, Ni, Co, Cr, Mn, and alloys of saidhard metals with each other; the ratio of hard metal to soft metal being from 1:4 to 4:1, and the particle size of the metal mixture being finer than 200 mesh, the mixture being suitable for application to steel prior to press forming and welding and being'non-conduetive and becoming conductive only when a pressure of 30 kg/cm is applied thereto and providing good paint adhesion after welding. I i

2. A precoated metal sheet coated and baked with the weldable paint composition of claim 1 and having a dry paint film of 8 20;; thickness.

3. A precoated metal sheet according to claim 2 in which the base metal sheet is one selected from the group consisting of plated metal sheets, chromated metal sheet and chemically converted metal sheet.

4. The weldable paint of claim 1 wherein graphite is substituted for a portion of said soft metal.

5. The weldable paint composition of claim 4 in which the metal powder and the graphite are of spherical or jagged shape.

6. In a method for preparing a weldable paint coated steel surface wherein a coating composition is applied to the steel surface and the coated steel is baked, the improvement wherein the coating composition of claim 1 is used.

7. In a weldable paint composition comprising a film forming resin and a conductive metal, the improvement wherein the metal comprises a mixture of powdered graphite; and a hard metal selected from the group consisting of Fe, Ni, Co, Cr, Mn, and alloys of said hard metals with each other; the ratio of hard metal to graphite being from 1:4 to 4:1, and the particle size of the mixture being finer than 200 mesh, the mixture being suitable for application to steel prior to press forming and welding and being non-conductive and becoming conductive only when a pressure of 30 kg/cm is applied thereto and providing good paint adhesion after welding. 

1. IN A WELDABLE PAINT COMPOSITION COMPRISING A FILM FORMING RESIN AND A CONDUCTIVE METAL, THE IMPROVEMENT WHEREIN THE METAL COMPRISES A MIXTURE OF A SOFT METAL SELECTED FROM THE GROUP CONSISTING OF AL,ZN, PB, CU, CD, MG, AG, SN, AND ALLOYS OF SAID SOFT METALS WITH EACH OTHER, AND A HARD METAL SELECTED FROM THE GROUP CONSISTING OF FE, NI, CO, CR, MN, AND ALLOYS OF SAID HARD METALS WITH EACH OTHER, THE RATIO OF HARD METAL TO SOFT METAL BEING FROM 1:4 TO 4:1, AND THE PARTICLE SIZE OF THE METAL MIXTURE BEING FINER THAN 200 MESH, THE MIXTURE BEING SUITABLE FOR APPLICATION TO STEEL PRIOR TO PRESS FORMING AND WELDING AND BEING NON-CONDUCTIVE AND BECOMING CONDUCTIVE ONLY WHEN A PRESSURE OF 30 KG/CM2 IS APPLIED THERETO AND PROVIDING GOOD PAINT ADHENSION AFTER WELDING.
 2. A precoated metal sheet coated and baked with the weldable paint composition of claim 1 and having a dry paint film of 8 -20 Mu thickness.
 3. A precoated metal sheet according to claim 2 in which the base metal sheet is one selected from the group consisting of plated metal sheets, chromated metal sheet and chemically converted metal sheet.
 4. The weldable paint of claim 1 wherein graphite is substituted for a portion of said soft metal.
 5. The weldable paint composition of claim 4 in which the metal powder and the graphite are of spherical or jagged shape.
 6. In a method for preparing a weldable paint coated steel surface wherein a coating composition is applied to the steel surface and the coated steel is baked, the improvement wherein the coating composition of claim 1 is used.
 7. In a weldable paint composition comprising a film forming resin and a conductive metal, the improvement wherein the metal comprises a mixture of powdered graphite; and a hard metal selected from the group consisting of Fe, Ni, Co, Cr, Mn, and alloys of said hard metals with each other; the ratio of hard metal to graphite being from 1:4 to 4:1, and the particle size of the mixture being finer than 200 mesh, the mixture being suitable for application to steel prior to press forming and welding and being non-conductive and becoming conductive only when a pressure of 30 kg/cm2 is applied thereto and providing good paint adhesion after welding. 